Abstract
This paper investigates the capability of linear thermal elastic numerical analysis to predict the welding distortion that occurs due to GMAW process. Distortion is considered as the major stumbling block that can adversely affect the dimensional accuracy and thus lead to expensive corrective work. Hence, forecast of distortion is crucially needed and ought to be determined in advance in order to minimize the negative effects, improve the quality of welded parts and finally to reduce the production costs. In this study, the welding deformation was simulated by using relatively new FEM software WELD PLANNER developed by ESI Group. This novel Welding Simulation Solution was employed to predict welding distortion induced in butt and T-joints with thickness of 4 mm. Low carbon steel material was used for the simulation and experimental study. A series of experiments using fully automated welding process were conducted for verification purpose to measure the distortion. By comparing between the simulation and experimental results, it was found out that this program code offered fast solution analysis time in estimating weld induced distortion within acceptable accuracy.
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This paper was recommended for publication in revised form by Editor Dae-Eun Kim
Yupiter HP Manurung is currently an Associate Professor at Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Malaysia. He received his BSc. in Manufacturing Technology from University of Applied Sciences GSO Nueremberg, Germany and his MSc. as well as PhD in Manufacturing Technology from University O-v-G Magdeburg, Germany. He also obtained International/European/German Welding Engineer (IWE/EWE/SFI) from SLV Halle, Germany and Laser Technology from University Jena, Germany. His research interests include advanced manufacturing technology, advanced welding technology and simulation and quality and reliability engineering.
Engr. Mohd Shahar Sulaiman is currently a Master’s student in Mechanical Engineering at Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Malaysia. He received his Diploma in Mechanical Engineering from UTM Malaysia in 2004 and BEng. in Mechanical Engineering from UiTM Malaysia in 2010.
Esa Haruman is currently a lecturer at Bakrie University, Jakarta, Indonesia. He was formerly Associate Professor at Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Malaysia. He received his BSc. in Material Science and Metallurgy from University of Indonesia and his MSc. and Ph.D in Metallurgical Manufacturing from University of Birmingham UK. His research interests include advanced materials, manufacturing process, heat treatment and surface engineering.
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Sulaiman, M.S., Manurung, Y.H., Haruman, E. et al. Simulation and experimental study on distortion of butt and T-joints using WELD PLANNER. J Mech Sci Technol 25, 2641–2646 (2011). https://doi.org/10.1007/s12206-011-0701-8
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DOI: https://doi.org/10.1007/s12206-011-0701-8